News and articles from Topstar

When the mold opening position of a plastic injection molding machine deviates by 3 mm per cycle, it causes flash (excess plastic) on precision parts, rendering them unusable. In industries such as medical, automotive, or electronics, part tolerances can be as small as ±0.5 mm, and even a 1 mm deviation can have serious consequences.… Continue reading How to solve the accuracy deviation of the mold opening position in a plastic injection molding machine?

Suppose an injection molding robot cannot maintain stable positioning, resulting in microscratches on parts and non-standard dimensions. In that case, it not only wastes significant production time and costs but also compromises part quality. Therefore, for high-precision applications and scenarios with stringent appearance requirements, specialized injection molding robots are necessary. Topstar’s HDW series, designed specifically… Continue reading How to Choose an Injection Molding Robot for High-Precision Products: HDW’s High-Speed ​​Response

At an automotive parts injection molding plant, 10,000 semi-finished sensor housings were left idle due to a 0.5-gram weight deviation in the plastic injection molding process. “We’ve adjusted the pressure knob 50 times today,” their production manager said. “One batch is too light, the next too heavy. We simply can’t guarantee consistent weight.” This situation… Continue reading How to Resolve Plastic Molding Part Weight Variations from Pressure Control？

Many manufacturers encounter the issue of poor back-pressure control in plastic molding machine, leading to average scrap rates of 8% to 12% and annual losses of tens of thousands of dollars per machine. Some packaging manufacturers have also scrapped defective bottles worth tens of thousands of dollars due to uneven wall thickness caused by unstable… Continue reading How to solve the problem of poor back-pressure control in a plastic molding machine?

Many injection molding plants fail to maintain a stable mold temperature of 160°C when producing high-temperature polymers, resulting in numerous scraps, rework, and mold damage. For example, a medical product manufacturer scrapped 1,200 PEEK components last year because its mold temperature was consistently maintained at 145°C—flow lines and warpage rendered these components unusable. Therefore, mastering… Continue reading Mastering the 160℃ mold temperature controller: Which materials require 160℃?

Damage to the clamping platen in an electric injection molding machine can lead to unplanned downtime, parts scrap, and additional emergency repair costs. As an injection molding machine manufacturer, we recognize that the root cause lies in insufficient platen design strength, which cannot withstand the high precision and high-strength forces required by electric injection molding… Continue reading How to solve platen damage problems: High-rigidity platen design for electric injection molding machine

Two common mistakes are easily made when injection molding TPU/TPE: using injection pressures below 1400 kgf/cm² and using standard (non-nitrided) screws and barrels. TPU and TPE offer unparalleled flexibility and durability, but their unique flowability and abrasion resistance require specialized process control to achieve optimal results. Therefore, several key considerations must be taken into account… Continue reading Injection Molding of Flexible Materials: Precautions for TPU/TPE Processes

Unplanned downtime in injection molding often stems from nozzle clogging, resulting in an average loss of hundreds of dollars per hour in production. A Michigan-based auto parts manufacturer reported losing over a dozen hours per month due to nozzle clogging, resulting in significant waste of production time. Nozzle clogging, caused by solidified molten plastic or… Continue reading Learn how to quickly solve molding machine nozzle clogging problems in 5 minutes

Unstable plasticization, inaccurate demolding, and excessively long production cycles lead to significant losses in production efficiency. On average, each factory loses tens of thousands of dollars annually due to PP material waste and failure to meet production targets. As product managers at Topstar, we’ve heard many clients raise these issues. One large home appliance brand… Continue reading Case Study: Injection Molding of Rice Cooker Shell Using a 260-Ton Injection Molding Machine

A 2024 survey found that 32% of production scrap and 18% of cycle time extensions in injection molding were attributed to poorly performing mold temperature controllers. In actual production, a water-type mold temperature controller operating with a 2°C deviation can reduce yield from 95% to 85% overnight. You can’t just set up a mold temperature… Continue reading 2025 Optimization Checklist: Methods to Improve the Performance of Any Mold Temperature Controller

Manufacturers across many regions lose 15% to 20% of their production time due to communication delays and parameter loss in traditional hydraulic or basic electric injection molding machines. For a 24/7 factory, this translates to 1,080 hours of wasted production annually and millions of dollars in lost revenue. Even worse, 4% to 8% of parts… Continue reading Digital Platform All Electric Injection Molding Machine: Enhance Efficiency & Parameter Control

Every year, many manufacturers waste 5-10% of their raw materials due to degradation, equivalent to significant resource losses for a medium-sized enterprise operating 24/7. Worse still, these manufacturers fail to realize that degradation is the root cause of part defects. As an injection molding machine manufacturer, I’ve found that 70% of degradation cases are due… Continue reading How can I prevent material degradation by adjusting the molding machine barrel temperature?